Service Procedure

1. With the ignition key in the OFF position, disconnect the negative battery cable.

Note:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.

2. Remove the fuel tank filler tube cap.

WARNING:
The fuel system may be under pressure even with the engine off. Before removing the fuel tank, the fuel system pressure must be released.

3. Remove the protective cap from the pressure test port on the fuel rail. The test port is located on the top of the fuel rail near the throttle position sensor.

4. Place one end of the fuel hose from the fuel pressure gauge tool set 5069 into an approved gasoline container.

5. Place a shop towel under the test port.

6. Release the fuel pressure by attaching the other end of the fuel hose onto the fuel pressure test port.

7. Remove the fuel hose and reinstall the test port cap.

8. Raise the vehicle on an appropriate hoist.





9. Disconnect the fuel filler and fuel vent hoses from the fuel tank (Figure 1).

10. Insert a fuel drain/siphon hose into the tank filler tube nipple and drain the fuel into an approved gasoline holding tank.

11. Place a transmission jack under the center of the fuel tank. Apply a slight amount of pressure to the fuel tank with the transmission jack.





12. Remove the fuel tank mounting strap nuts (Figure 2).

13. Remove the fuel tank heat shield (if equipped).

14. Lower the tank no more than three inches (3") to provide access to the fuel pump module connections.

CAUTION:
Do not lower the tank more than three inches or damage to the fuel hose may result.





15. Disconnect the fuel supply hose from the fuel filter/pressure regulator (Figure 3).

16. Disconnect the electrical connector from the fuel pump module (Figure 3).

17. Disconnect the vapor hose from the rollover valve (Figure 3).

18. Lower the fuel tank and set it on the floor.





19. Remove the rollover valve from the fuel pump module. To do this, lift one of the squared-off corners of the valve with a small screwdriver or trim stick, then grasp the outer diameter of the valve with large adjustable or locking pliers and roll the valve out of the rubber grommet (Figure 4).

CAUTION:
DO NOT use a screwdriver or other sharp tool to pry the valve out of the grommet as this may damage the grommet and cause a fuel leak.

20. Using finger pressure only, press the supplied rollover valve into the rubber grommet (Figure 4).

NOTE:
Coat the valve sealing lip with soapy water to aid installation.

21. Place the fuel tank back onto the transmission jack and raise the tank to within three inches of its seated position (for access to hose and wiring connections).

22. Connect the fuel pump module electrical connector (Figure 3). Make sure that the locking tab is engaged.

23. Connect the vapor hose to the rollover valve (Figure 3).

24. Connect the fuel supply hose to the fuel filter/pressure regulator (Figure 3).

25. Install the fuel tank heat shield (if equipped).

26. Fully raise tank into position and install the two mounting straps and nuts (Figure 2). Tighten the nuts to 30 ft-lbs (41 N.m). Do NOT over tighten.

27. Connect the fuel filler and vent tubes to the fuel tank (Figure 1). Tighten the hose clamps to 20 in-lbs (2.3 N.m).

28. Lower the vehicle.

29. Refill the fuel tank, install the filler cap and check for leaks.

30. Connect the negative battery cable.